Extraction solvent control for reducing stable emulsions

ABSTRACT

Disclosed herein are methods for recovering diphosphite-containing compounds from mixtures comprising organic mononitriles and organic dinitriles, using liquid-liquid extraction. Also disclosed are treatments to enhance extractability of the diphosphite-containing compounds.

RELATED APPLICATION

This application claims benefit to Provisional Application No. 61/578,508 filed Dec. 21, 2011 which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The invention relates to recovery of catalyst and ligand from a hydrocyanation reaction product mixture comprising organic dinitriles using liquid-liquid extraction.

BACKGROUND OF THE INVENTION

It is well known in the art that complexes of nickel with phosphorous-containing ligands are useful as catalysts in hydrocyanation reactions. Such nickel complexes using monodentate phosphites are known to catalyze hydrocyanation of butadiene to produce a mixture of pentenenitriles. These catalysts are also useful in the subsequent hydrocyanation of pentenenitriles to produce adiponitrile, an important intermediate in the production of nylon. It is further known that bidentate phosphite and phosphinite ligands can be used to form nickel-based catalysts to perform such hydrocyanation reactions.

U.S. Pat. No. 3,773,809 describes a process for the recovery of Ni complexes of organic phosphites from a product fluid containing organic nitriles produced by hydrocyanating an ethylenically unsaturated organic mononitrile such as 3-pentenenitrile through extraction of the product fluid with a paraffin or cycloparaffin hydrocarbon solvent. Similarly, U.S. Pat. No. 6,936,171 to Jackson and McKinney discloses a process for recovering diphosphite-containing compounds from streams containing dinitriles.

U.S. Pat. No. 4,339,395 describes the formation of an interfacial rag layer during extended periods of continuous extraction of certain phosphite ligands. The '395 patent notes that the interfacial rag hinders, if not halts, the phase separation. Because the process is operated continuously, the rag must be removed continuously from the interface as it accumulates to avoid interrupting operation. To solve this problem for the disclosed components, the '395 patent discloses the addition of minor amounts of substantially water-free ammonia.

SUMMARY OF THE INVENTION

This process recovers diphosphite-containing compounds from a mixture comprising diphosphite-containing compounds, organic mononitriles and organic dinitriles.

Disclosed is a process for recovering diphosphite-containing compounds from a feed mixture comprising diphosphite-containing compounds, organic mononitriles and organic dinitriles in a multistage countercurrent liquid-liquid extractor with extraction solvent comprising aliphatic hydrocarbon, cycloaliphatic hydrocarbon or a mixture of aliphatic and cycloaliphatic hydrocarbon, comprising:

a) flowing the feed mixture to the first stage of the multistage countercurrent liquid-liquid extractor; and b) contacting the feed mixture with extraction solvent in the multistage countercurrent liquid-liquid extractor;

wherein the first stage of the multistage countercurrent liquid-liquid extractor comprises a mixing section and a settling section, wherein a light phase separates from a heavy phase in the settling section, wherein the light phase comprises extraction solvent and extracted diphosphite-containing compounds, wherein the heavy phase comprises organic mononitriles and organic dinitriles, wherein a first portion of the light phase is withdrawn from the settling section and treated to recover diphosphite-containing compounds extracted into the light phase, and wherein a second portion of the light phase is withdrawn from the settling section and recycled to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor.

The mixing sections of the stages of the multistage counter current liquid-liquid extractor form an intimate mixture of unseparated light and heavy phase. This intimate mixture comprises an emulsion phase. The emulsion phase may or may not comprise particulate solid material. This emulsion phase separates into a light phase and a heavy phase in the settling sections of the stages, including the first stage. Accordingly, the settling sections of the stages will contain at least some emulsion phase located between the upper light phase and the lower heavy phase. This emulsion phase tends to reduce in size over time. However, in some instances settling takes longer than desired or the emulsion phase never fully separates into a light phase and a heavy phase. This separation problem may be particularly troublesome in the first stage of a multistage countercurrent liquid-liquid extractor.

Recycle of light phase from the separation section of the first stage to the mixing section of the first stage has been found to result in enhanced settling of the emulsion phase. For example, this recycle may result in the reduction of the size of the emulsion phase in the settling section, wherein the size of the emulsion phase is based upon the size of the emulsion phase in the absence of recycle of the light phase. Enhanced settling in the settling section may also be measured as an increased rate of settling, based upon the rate of settling in the absence of recycle of the light phase.

Another problem, which may be solved by recycle of light phase is formation of rag and build-up of a rag layer the settling section. Rag formation is discussed in U.S. Pat. No. 4,339,395 and U.S. Pat. No. 7,935,229. Rag comprises particulate solid material, and may be considered to be a form of an emulsion phase, which is particularly stable in the sense that it does not dissipate in a practical amount of time for conducting an extraction process. Rag may form in the mixing section or the settling section of an extraction stage, particularly the first stage of a multistage countercurrent liquid-liquid extractor. In the settling section, the rag forms a layer between the heavy phase and the light phase. The formation of a rag layer in the settling section inhibits proper settling of the heavy phase and the light phase. The formation of a rag layer may also inhibit the extraction of diphosphite-containing compounds from the heavy phase into the light phase. In a worst case scenario, rag can build up to extent of completely filling a separation section, necessitating shut down of the extraction process to clean out the settling section. It has been found that recycle of light phase from the settling section to the mixing section may reduce or eliminate the size of a rag layer or reduce its rate of formation, based upon the size and rate of formation of the rag layer in the absence of recycle of the light phase.

Accordingly, recycle of light phase from the settling section to the mixing section of the first stage of a multistage countercurrent extractor may achieve at least one of the following results: (a) a reduction in the size of an emulsion phase in the settling section, based upon the size of the emulsion phase in the absence of recycle of the light phase; (b) an increase in the rate of settling in the settling section, based upon the rate of settling in the absence of recycle of the light phase; (c) an increase in the amount of diphosphite-containing compounds in the light phase, based upon the upon the amount of diphosphite-containing compounds in the light phase in the absence of recycle of the light phase; (d) a partial or total reduction in the size of a rag layer in the settling section, based upon the size of a rag layer in the settling section in the absence of recycle of the light phase; and (e) reduction in the rate of formation of a rag layer in the settling section, based upon the rate of formation of a rag layer in the settling section in the absence of recycle of the light phase.

The second portion of the light phase, which is recycled in the first stage, may be recycled to the mixing section in the absence of an intervening step to remove diphosphite-containing compounds from the light phase.

The second portion of the light phase, which is recycled in the first stage, may be recycled to the mixing section in the absence of passing through another liquid-liquid extraction stage.

The extraction solvent feed from the second stage of the multistage countercurrent liquid-liquid extractor to the first stage of the multistage countercurrent liquid-liquid extractor may comprise at least 1000 ppm, for example, from 2000 to 5000 ppm, of diphosphite-containing compounds. The extraction solvent feed from the second stage may comprise at least 10 ppm, for example, from 20 to 200 ppm, of nickel.

An extraction solvent recycle ratio (ESRR) may be between 0.1 and 0.9, for example, between 0.2 and 0.8, wherein ESRR is defined by the ratio of X to Y, wherein X is the mass per unit time of the second portion of the light phase recycled to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor, and wherein Y is the mass per unit time of all extraction solvent charged to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor.

The diphosphite-containing compound may be a Ni complex with a diphosphite ligand selected from the group consisting of:

wherein in I, II and III, R¹ is phenyl, unsubstituted or substituted with one or more C₁ to C₁₂ alkyl or C₁ to C₁₂ alkoxy groups; or naphthyl, unsubstituted or substituted with one or more C₁ to C₁₂ alkyl or C₁ to C₁₂ alkoxy groups; and wherein Z and Z¹ are independently selected from the group consisting of structural formulae IV, V, VI, VII, and VIII:

and wherein

R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, and R⁹ are independently selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy;

X is O, S, or CH(R¹⁰);

R¹⁶ is H or C₁ to C₁₂ alkyl;

and wherein

R¹¹ and R¹² are independently selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy and CO₂R¹³,

R¹³ is C₁ to C₁₂ alkyl, or C₆ to C₁₀ aryl unsubstituted or substituted with C₁ to C₄ alkyl;

Y is O, S, or CH(R¹⁴);

R¹⁴ is H or C₁ to C₁₂ alkyl;

wherein

R¹⁵ is selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy and CO₂R¹⁶,

R¹⁶ is C₁ to C₁₂ alkyl, or C₆ to C₁₀ aryl, unsubstituted or substituted with C₁ to C₄ alkyl,

and wherein

for structural formulae I through VIII, the C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy groups may be straight chain or branched.

At least one stage of the extraction may be carried out above 40° C.

At least one stage of extraction may contain a Lewis base.

If at least one stage of extraction contains a Lewis base, the Lewis base may be a monodentate triarylphosphite, wherein the aryl groups are unsubstituted or substituted with alkyl groups having 1 to 12 carbon atoms, and wherein the aryl groups may be interconnected.

The Lewis base may optionally be selected from the group consisting of:

a) anhydrous ammonia, pyridine, alkylamine, dialkylamine, trialkylamine wherein the alkyl groups have 1 to 12 carbon atoms; and b) polyamine.

If the Lewis base is a polyamine, the polyamine may comprise at least one selected from hexamethylene diamine, and dimers and trimers of hexamethylene diamine, for example, bis-hexamethylene triamine.

The Lewis base may optionally comprise a basic ion exchange resin, for example, Amberlyst 21® resin.

One example of a suitable cyclic alkane extraction solvent is cyclohexane.

At least a portion of the process may be carried out in an extraction column or a mixer-settler.

The feed mixture may be an effluent stream from a hydrocyanation process, for example, a process for hydrocyanating 3-pentenenitrile, a process for the single hydrocyanation of 1,3-butadiene to pentenenitriles or a process for the double hydrocyanation of 1,3-butadiene to adiponitrile.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing the flow of fluids through a multistage countercurrent liquid-liquid extractor.

FIG. 2 is a diagram showing recycle of light phase from a settling section to the mixing section of a stage of a multistage countercurrent liquid-liquid extractor.

FIG. 3 is a diagram showing recycle of light phase from a settling section to the mixing section of an extraction column.

FIG. 4 is a diagram showing recycle of light phase from a settling section to the mixing section of a mixing/settling apparatus having three chambers in the settling section.

DETAILED DESCRIPTION OF THE INVENTION

The processes of the present invention involve methods for recovering diphosphite-containing compounds from a mixture comprising diphosphite-containing compounds and organic dinitriles, using liquid-liquid extraction.

FIG. 1 is a diagram of a multistage countercurrent liquid-liquid extractor. Lines in FIG. 1 represent flow of materials, rather than any particular type of equipment, such as pipes. Similarly, squares in this diagram represent stages or sections for mixing and settling, rather than any particular type of equipment.

Three stages are depicted in FIG. 1. The first stage is depicted by mixing and settling section 1. The second stage is depicted by mixing and settling section 2. The final stage is depicted by mixing and settling section 3. Gap 30 represents a space where additional stages may be inserted. For example, one or more, for example, from one to four, mixing and settling sections may be inserted in gap 30 between mixing and settling section 2 and mixing and settling section 3.

In FIG. 1, a fresh extraction solvent feed, for example, cyclohexane, is introduced into the multistage countercurrent extractor via line 10. The extraction solvent or light phase exiting from mixing settling section 3 passes through line 12 to the next stage of the multistage extractor. In a multistage countercurrent liquid-liquid extractor having three stages, extraction solvent in line 12 would pass directly into stage 2 via line 14. Extraction solvent from stage 2 passes through line 16 to stage 1. The extraction solvent comprising extracted diphosphite-containing compounds passes out of the stage 1 mixing and settling section through line 18.

A feed comprising diphosphite-containing compounds is fed into the stage 1 mixer and settler via line 20. The feed further comprises a mixture comprising organic mononitriles and dinitriles, which is immiscible with the extraction solvent. In stage 1, a portion of the diphosphite-containing compounds is extracted into the extraction solvent which exits stage 1 via line 18. The immiscible dinitrile and mononitrile mixture or the heavy phase is removed from the stage 1 mixing and settling section by line 22 and is passed into the stage 2 mixing and settling section. A portion of the diphosphite-containing compounds is extracted into the light phase in the stage 2 mixing and settling section. The heavy phase exits the stage 2 mixing and settling section by line 24. Similarly, if there are additional stages in gap 30 shown in FIG. 1, extraction of diphosphite-containing compounds will take place in such intermediate stages in a similar manner to that taking place in stage 2.

After the heavy phase passes through the first stage and any intermediate stages, it passes through the final stage mixing and settling section 3. In particular, the heavy phase is introduced into mixing and setting section 3 through line 26. After passing through the final stage mixing and settling section 3, the heavy phase exits via line 28.

A two-stage multistage countercurrent liquid-liquid extractor is represented in FIG. 1 by mixing and settling sections 1 and 2; lines 14, 16 and 18 showing the direction of extraction solvent flow; and lines 20, 22 and 24 showing the direction of heavy phase flow. In a two-stage multistage counter current liquid-liquid extractor, mixing and settling section 3; lines 10, 12, 26 and 28; and gap 30 are omitted. In the two stage countercurrent liquid-liquid extractor, extraction solvent comprising extracted diphosphite-containing compounds passes from the extractor through line 18, and extracted heavy phase, i.e. raffinate, passes from the extractor through line 24.

Thus, it can be seen that the multistage countercurrent liquid-liquid extractor comprises two or more stages with countercurrent flow of extraction solvent and heavy phase.

FIG. 2 is a diagrammatic representation of one type of a mixing and settling section, also referred to herein as a mixer-settler. This type of mixer-settler may be used in any of the stages shown in FIG. 1. This mixer-settler comprises a mixing section 40 and a settling section 50. An extraction solvent is introduced into the mixing section 40 by line 42. A feed comprising diphosphite-containing compounds is introduced into the mixing section 40 by line 44. Alternatively, the contents of lines 42 and 44 may be combined upstream of the mixing section 40 and introduced into mixing section 40 through a single inlet. These two feeds are mixed in the mixing section 40 to provide an emulsion phase represented in FIG. 2 by shaded area 46.

Line 48 represents the flow of emulsion phase 46 from the mixing section 40 into the settling section 50. As depicted in FIG. 2, there are three phases in the settling section 50, including a heavy phase 52, an emulsion phase 54, and a light phase 56. The heavy phase 52 is depleted in diphosphite-containing compounds, insofar as it has a lower concentration of diphosphite-containing compounds as compared with the concentration of diphosphite-containing compounds in feed 44, due to the extraction of diphosphite-containing compounds into the light phase 56. Correspondingly, the light phase 56 is enriched in diphosphite-containing compounds, insofar as it has a higher concentration of diphosphite-containing compounds as compared with the concentration of diphosphite-containing compounds in extraction solvent feed 42, due to the extraction of diphosphite-containing compounds into the light phase 56. Heavy phase 52 exits the settling section 50 via line 58. A portion of the light phase 56 is removed from the settling section 50 via line 60, and another portion of the light phase 56 is removed from the settling section 50 via line 62. The portion of light phase 56 in line 62 is introduced into the mixing section 40 as a recycle feed. Alternatively, line 62 may be taken as a side stream from line 60, instead of directly from settling section 50. In another alternate embodiment, line 62 may flow into lines 42 or 44, instead of directly into mixing section 40.

Although not shown in FIG. 2, which is diagrammatically shows the flow of fluids, it will be understood that each of the mixing section 40 and the settling section 50 may comprise one or more stages, subsections, compartments or chambers. For example, settling section 50 may include more than one chamber between the point of introduction of emulsion phase through line 48 and the point of withdrawal of light phase and heavy phase through lines 58, 60 and 62. The size of the emulsion phase may become progressively smaller as fluids settle and flow through the chamber. For example, the final chamber from where fluids are removed may include little or no emulsion phase 54. It will further be understood that mixing section 40 may include one or more types of mixing apparatus, such as an impeller, not shown in FIG. 2.

FIG. 3 provides a representation of another type of apparatus for use as a mixing and settling section. The type of apparatus 70 shown in FIG. 3 is referred to herein as an extraction column. This extraction column 70 includes a mixing section 72, a heavy phase collection section 74 and a light phase collection section 76. The entire column 70 may be considered to be a settling section with a mixing section between collection section 74 and collection section 76. In extraction column 70 the mixing section 72 is part of the settling section. An extraction solvent is introduced into column 70 through line 80. A heavier phase comprising a diphosphite-containing compound is introduced into column 70 through line 90. As the light phase passes upward through the column, and the heavy phase passes downward through the column, a mixture of the two phases is formed in mixing section 72. This mixture is represented in FIG. 3 as shaded emulsion phase 84. The point of introduction of heavy phase through line 90 should be sufficiently above the point of introduction of the light phase to allow for sufficient mixing of the two phases in the mixing section resulting in the extraction of diphosphite-containing compounds into the light phase. The intimate mixing of light and heavy phase in mixing section 72 may be promoted by mechanical or static mixing apparatus not shown in FIG. 3. For example, mixing section 72 may comprise baffles or perforated plates, not shown in FIG. 3.

The heavy phase 82 settles into collection section 74 and passes out of the column 70 through line 96. Light phase 86 settles in collection section 76 and passes from the column through line 92. A portion of this separated light phase is taken as a side stream through line 94 and is passed into line 80 for recycle into column 70. Alternatively, line 94 may be taken directly from collection section 76, instead of as a side stream from line 92. In another alternate embodiment, line 94 may flow directly into column 72 at a point near the bottom of the mixing section 72, instead of into line 80.

FIG. 4 provides a representation of a mixer-settler 100 having a multistage settling section. Mixer-settler 100 has a mixing section 110 and a settling section 112. In mixer-settler 100, the mixing section 110 is separate from the settling section 112. The settling section has three compartments, represented in FIG. 4 as sections 114, 116, and 118. These sections are separated by coalescence plates 120. The coalescence plates 120 may be designed to provide flow of separated light and heavy phases between chambers, while restricting the flow of emulsion phase between chambers. A feed comprising a diphosphite-containing compound is passed into the mixing section 110 via line 130. The extraction solvent is introduced into mixing section 110 via line 132. The mixing section 110 includes an impeller 134 mounted on shaft 136 to provide for mechanical mixing of fluids. Mixing of the feeds provides a mixed phase comprising an emulsion phase represented in FIG. 4 by shading 140.

The mixed phase 140 flows into the settling section 112 as an overflow from the mixing section 110. This emulsion phase 140 is prevented from flowing directly into the light phase 144 by baffle plate 142. As settling occurs in settling section 112, the emulsion phase 140 decreases in volume, the volume of the light phase 144 increases, and the volume of the heavy phase 146 increases. Heavy phase 146 is removed from settling section 112, in particular from chamber 118, via line 152 and light phase 144 is removed from settling section 112, in particular from chamber 118, via line 150. A portion of the light phase removed through line 150 is taken as a side stream through a line not shown in FIG. 4 and combined with the feed in line 132 as a source of extraction solvent feed to mixing section 110.

It is desirable for both a mononitrile and a dinitrile to be present in the countercurrent contactor. For a discussion of the role of monodentate and bidentate ligand in extraction of hydrocyanation reactor effluent streams, see U.S. Pat. No. 3,773,809 to Walter and U.S. Pat. No. 6,936,171 to Jackson and McKinney.

For the process disclosed herein, suitable ratios of mononitrile to dinitrile components include 0.01 to 2.5, for example, 0.01 to 1.5, for example 0.65 to 1.5.

Maximum temperature is limited by the volatility of the hydrocarbon solvent utilized, but recovery generally improves as the temperature is increased. Examples of suitable operating ranges are 40° C. to 100° C. and 50° C. to 80° C.

The controlled addition of monophosphite ligands may enhance settling. Examples of monophosphite ligands that may be useful as additives include those disclosed in Drinkard et al U.S. Pat. No. 3,496,215, U.S. Pat. No. 3,496,217, U.S. Pat. No. 3,496,218, U.S. Pat. No. 5,543,536, and published PCT Application WO 01/36429 (BASF).

The addition of Lewis base compounds to a mixture comprising diphosphite-containing compounds, organic mononitriles and organic dinitriles may enhance settling, especially when the mixture comprises a Lewis acid, such as ZnCl₂. The addition may take place either before or during an extraction process in a multistage countercurrent extractor. Examples of suitable weak Lewis base compounds include water and alcohols. Suitable stronger Lewis base compounds include hexamethylene diamine, and dimers and trimers of hexamethylene diamine, ammonia, aryl- or alkyl amines, such as pyridine or triethylamine, or basic resins such as Amberlyst 21°, a commercially available basic resin made by Rohm and Haas. The addition of Lewis base may reduce or eliminate any inhibiting effect of Lewis acid on catalyst recovery.

The diphosphite-containing compounds extracted by the processes described herein are also referred to herein as bidentate phosphorus-containing ligands. These extracted ligands comprise free ligands (e.g., those which are not complexed to a metal, such as nickel) and those which are complexed to a metal, such as nickel. Accordingly, it will be understood that extraction processes described herein are useful for recovering diphosphite-containing compounds which are metal/ligand complexes, such as a complex of zero valent nickel with at least one ligand comprising a bidentate-phosphorus containing ligand.

Suitable ligands for extraction are bidentate phosphorous-containing ligands selected from the group consisting of bidentate phosphites, and bidentate phosphinites. Preferred ligands are bidentate phosphite ligands.

Diphosphite Ligands

Examples of bidentate phosphite ligands useful in the invention include those having the following structural formulae:

wherein in I, II and III, R¹ is phenyl, unsubstituted or substituted with one or more C₁ to C₁₂ alkyl or C₁ to C₁₂ alkoxy groups; or naphthyl, unsubstituted or substituted with one or more C₁ to C₁₂ alkyl or C₁ to C₁₂ alkoxy groups; and Z and Z¹ are independently selected from the group consisting of structural formulae IV, V, VI, VII, and VIII:

and wherein

R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, and R⁹ are independently selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy;

X is O, S, or CH(R¹⁰);

R¹⁰ is H or C₁ to C₁₂ alkyl;

and wherein

R¹¹ and R¹² are independently selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy; and CO₂R¹³,

R¹³ is C₁ to C₁₂ alkyl or C₆ to C₁₀ aryl, unsubstituted or substituted. with C₁ to C₄ alkyl;

Y is O, S, or CH(R¹⁴);

R¹⁴ is H or C₁ to C₁₂ alkyl;

wherein

R¹⁵ is selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy and CO₂R¹⁶;

R¹⁶ is C₁ to C₁₂ alkyl or C₆ to C₁₀ aryl, unsubstituted or substituted with C₁ to C₄ alkyl.

In the structural formulae I through VIII, the C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy groups may be straight chain or branched.

Another example of a formula of a bidentate phosphite ligand that is useful in the present process is that having the Formula X, shown below

Further examples of bidentate phosphite ligands that are useful in the present process include those having the Formulae XI to XIV, shown below wherein for each formula, R¹⁷ is selected from the group consisting of methyl, ethyl or isopropyl, and R¹⁸ and R¹⁹ are independently selected from H or methyl:

Additional examples of bidentate phosphite ligands that are useful in the present process include a ligand selected from a member of the group represented by Formulae XV and XVI, in which all like reference characters have the same meaning, except as further explicitly limited:

wherein

R⁴¹ and R⁴⁵ are independently selected from the group consisting of C₁ to C₅ hydrocarbyl, and each of R⁴², R⁴³, R⁴⁴, R⁴⁶, R⁴⁷ and R⁴⁸ is independently selected from the group consisting of H and C₁ to C₄ hydrocarbyl.

For example, the bidentate phosphite ligand can be selected from a member of the group represented by Formula XV and Formula XVI, wherein

R⁴¹ is methyl, ethyl, isopropyl or cyclopentyl;

R⁴² is H or methyl;

R⁴³ is H or a C₁ to C₄ hydrocarbyl;

R⁴⁴ is H or methyl;

R⁴⁵ is methyl, ethyl or isopropyl; and

R⁴⁶, R⁴⁷ and R⁴⁸ are independently selected from the group consisting of H and C₁ to C₄ hydrocarbyl.

As additional examples, the bidentate phosphite ligand can be selected from a member of the group represented by Formula XV, wherein

R⁴¹, R⁴⁴, and R⁴⁵ are methyl;

R⁴², R⁴⁶, R⁴⁷ and R⁴⁸ are H; and

R⁴³ is a C₁ to C₄ hydrocarbyl;

or

R⁴¹ is isopropyl;

R⁴² is H;

R⁴³ is a C₁ to C₄ hydrocarbyl;

R⁴⁴ is H or methyl;

R⁴⁵ is methyl or ethyl;

R⁴⁶ and R⁴⁸ are H or methyl; and

R⁴⁷ is H, methyl or tertiary-butyl;

or the bidentate phosphite ligand can be selected from a member of the group represented by Formula XVI, wherein

R⁴¹ is isopropyl or cyclopentyl;

R⁴⁵ is methyl or isopropyl; and

R⁴⁶, R⁴⁷, and R⁴⁸ are H.

As yet another example, the bidentate phosphite ligand may be represented by Formula XV, wherein R⁴¹ is isopropyl; R⁴², R⁴⁶, and R⁴⁸ are H; and R⁴³, R⁴⁴, R⁴⁵, and R⁴⁷ are methyl.

It will be recognized that Formulae X to XVI are two-dimensional representations of three-dimensional molecules and that rotation about chemical bonds can occur in the molecules to give configurations differing from those shown. For example, rotation about the carbon-carbon bond between the 2- and 2′-positions of the biphenyl, octahydrobinaphthyl, and or binaphthyl bridging groups of Formulae X to XVI, respectively, can bring the two phosphorus atoms of each Formula in closer proximity to one another and can allow the phosphite ligand to bind to nickel in a bidentate fashion. The term “bidentate” is well known in the art and means both phosphorus atoms of the ligand are bonded to a single nickel atom.

Further examples of bidentate phosphite ligands that are useful in the present process include those having the formulae XX to LIII, shown below wherein for each formula, R¹⁷ is selected from the group consisting of methyl, ethyl or isopropyl, and R¹⁸ and R¹⁹ are independently selected from H or methyl:

Additional suitable bidentate phosphites are of the type disclosed in U.S. Pat. Nos. 5,512,695; 5,512,696; 5,663,369; 5,688,986; 5,723,641; 5,847,101; 5,959,135; 6,120,700; 6,171,996; 6,171,997; 6,399,534; the disclosures of which are incorporated herein by reference. Suitable bidentate phosphinites are of the type disclosed in U.S. Pat. Nos. 5,523,453 and 5,693,843, the disclosures of which are incorporated herein by reference.

Extraction Solvent

Suitable hydrocarbon extraction solvents include paraffins and cycloparaffins (aliphatic and alicyclic hydrocarbons) having a boiling point in the range of about 30° C. to about 135° C., including n-pentane, n-hexane, n-heptane and n-octane, as well as the corresponding branched chain paraffinic hydrocarbons having a boiling point within the range specified. Useful alicyclic hydrocarbons include cyclopentane, cyclohexane and cycloheptane, as well as alkyl substituted alicyclic hydrocarbons having a boiling point within the specified range. Mixtures of hydrocarbons may also be used, such as, for example, mixtures of the hydrocarbons noted above or commercial heptane which contains a number of hydrocarbons in addition to n-heptane. Cyclohexane is the preferred extraction solvent.

The lighter (hydrocarbon) phase recovered from the multistage countercurrent liquid-liquid extractor is directed to suitable equipment to recover catalyst, reactants, etc. for recycle to the hydrocyanation, while the heavier (lower) phase containing dinitriles recovered from the multistage countercurrent liquid-liquid extractor is directed to product recovery after removal of any solids, which may accumulate in the heavier phase. These solids may contain valuable components which may also be recovered, e.g., by the process set forth in U.S. Pat. No. 4,082,811.

EXAMPLES

In the following examples, values for extraction coefficient are the ratio of weight fraction of catalyst in the extract phase (hydrocarbon phase) versus the weight fraction of catalyst in the raffinate phase (organonitrile phase). An increase in extraction coefficient results in greater efficiency in recovering catalyst. As used herein, the terms, light phase, extract phase and hydrocarbon phase, are synonymous. Also, as used herein, the terms, heavy phase, organonitrile phase and raffinate phase, are synonymous.

Example 1

To a 50 mL, jacketed, glass laboratory extractor, equipped with a magnetic stirbar, digital stir-plate, and maintained at 65° C., was charged 10 grams of the product of a pentenenitrile-hydrocyanation reaction, and 10 grams of the extract from the second stage of a mixer-settler cascade, operated in counter-current flow. The extract from the second stage contained approximately 50 ppm nickel and 3100 ppm diphosphite ligand.

The reactor product was approximately:

85% by weight C₆ dinitriles

14% by weight C₅ mononitriles

1% by weight catalyst components

360 ppm by weight active nickel.

The laboratory reactor was then mixed at 1160 rotations-per-minute, for 20 minutes, and then allowed to settle for 15 minutes. After settling for 15 minutes, a stable emulsion was present throughout the extract phase. Samples were obtained of the extract and raffinate phases of the extractor and analyzed to determine the extent of catalyst extraction. The ratio of active nickel present in the extract phase vs. the raffinate phase was found to be 14.

Example 2

Using the same hydrocyanation reactor product and 2^(nd) stage settler extract as Example 1, a 50 mL, jacketed, glass laboratory extractor, equipped with a magnetic stirbar, digital stir-plate, and maintained at 65° C., was charged 5 grams of the product of a pentene-hydrocyanation reaction, and 15 grams of the extract from the second stage of a mixer-settler cascade, operated in counter-current flow.

The laboratory reactor was then mixed at 1160 rotations-per-minute, for 20 minutes, and then allowed to settle for 15 minutes. After settling for 15 minutes, no emulsion was present in the extractor. Samples were obtained of the extract and raffinate phases of the extractor and analyzed to determine the extent of catalyst extraction. The ratio of active nickel present in the extract phase vs. the raffinate phase was found to be 14.

Example 3

Using the same hydrocyanation reactor product and 2nd stage settler extract as Example 1, a 50 mL, jacketed, glass laboratory extractor, equipped with a magnetic stirbar, digital stir-plate, and maintained at 65° C., was charged 6 grams of the product of a pentene-hydrocyanation reaction, and 12 grams of the extract from the second stage of a mixer-settler cascade, operated in counter-current flow.

The laboratory reactor was then mixed at 1160 rotations-per-minute, for 20 minutes, and then allowed to settle for 15 minutes. After settling for 15 minutes, no emulsion was present in the extractor. Samples were obtained of the extract and raffinate phases of the extractor and analyzed to determine the extent of catalyst extraction. The ratio of active nickel present in the extract phase vs. the raffinate phase was found to be 18.

Examples 1-3 illustrate the beneficial effect of increasing extract-to-dinitrile ratio on the extraction, and provide a practical simulation of the effect of recycle of the light phase in continuous operation.

TABLE 1 Catalyst and ligand extraction coefficient for various final stage extraction coefficient recycle ratios. Example RRR Catalyst Recovery (KLL) Stable Emulsion 1 0 14 Yes 2 0.5 14 No 3 0.7 18 No KLL = amount of catalyst in the extract/amount of catalyst in the raffinate

Examples 4-8

These Examples 4-8 illustrate that effective catalyst recovery occurs for a mononitrile to dinitrile ratio greater than 0.65.

Five different mixtures comprised of a Ni diphosphite complex, with the diphosphite ligand shown in Structure XX (where R¹⁷ is isopropyl, R¹⁸ is H, and R¹⁹ is methyl), ZnCl₂ (equimolar with Ni) and differing in the ratio of mononitrile to dinitrile, were separately liquid-liquid batch extracted with an equal weight of cyane (i.e. cyclohexane). The molar ratio of organic mononitrile to organic dinitrile and the resulting extraction coefficients are shown in the Table 2 below. A compound may be effectively recovered if it has an extraction coefficient of 1 or greater at solvent to feed ratios greater than 1 using a countercurrent multistage extractor.

TABLE 2 Catalyst and ligand extraction coefficients for varying ratios of mononitriles-to-dinitriles Catalyst extraction Ligand extraction Example mononitrile/dinitrile coefficient coefficient 1 2.33 1.28 4.09 2 1.85 1.33 8.08 3 1.19 2.02 16.97 4 0.91 2.63 35.99 5 0.57 4.82 49.59

Example 9

This Example demonstrates the effect of hold-up time on the extractability of the diphosphite ligand catalyst.

A mixture comprised predominantly of organic dinitriles and a Ni diphosphite complex, the structure of the diphosphite ligand being shown in Structure XX (where R¹⁷ is isopropyl, R¹⁸ is H, and R¹⁹ is methyl) and ZnCl₂ (equimolar with Ni) was divided into two portions. Both portions are liquid-liquid extracted in a three-stage contactor at 40° C., with an equal weight of cyclohexane. Both portions were sampled with time and the progress of the catalyst recovery into the extract phase is shown in Table 3 as the percent of the final steady state value achieved at a given time.

TABLE 3 Concentration of Diphosphite ligand with time in the extracting solvent phase. Time, % of steady state minutes concentration at 40° C. 2 12 4 19 8 34 14 52 30 78 60 100 91 100

Example 10

This Example illustrates the effect of temperature on the extractability of catalyst with last-stage extraction solvent recycle.

A mixture comprised predominantly of organic dinitriles and a Ni diphosphite complex, the structure of the diphosphite ligand being shown in Structure XXIV (where R¹⁷ is methyl, R¹⁸ is methyl and R¹⁹ is H) and ZnCl₂ (equimolar with Ni) was divided into three portions. The portions were batch liquid-liquid extracted at 50° C., 65° C. and 80° C., respectively, with an equal weight of n-octane and monitored with time. The results are shown in Table 4.

TABLE 4 % of steady state % of steady state at % of steady state at Time at 50° C. 65° C. 80° C. 2 0.0 0.0 1.8 4 0.0 0.0 1.6 8 0.0 0.0 3.6 14 0.0 0.0 4.3 20 0.0 0.0 3.6 30 0.0 0.0 7.6 60 0.0 1.6 16.3 90 0.7 4.0 48.6

Example 11

This Example demonstrates the effect of adding water in three-stage extraction with cyclohexane recycle in the last stage.

Fifteen grams of a mixture comprised predominantly of organic dinitriles and a Ni diphosphite complex, the structure of the diphosphite ligand being shown in Structure XXIV (where R¹⁷ is methyl, R¹⁸ is methyl and R¹⁹ is H) and ZnCl₂ (equimolar with Ni), was extracted in a three-stage continuous extractor at a temperature of 50° C. with an equal weight of cyclohexane for one hour resulting in an catalyst extraction coefficient of 4.3, as measured by the amount of catalyst in the extract of the first stage divided by the amount of catalyst in the feed of the reaction mixture fed to the last stage of the three-stage countercurrent extractor.

To this mixture, 100 microliters of water was added. After continuing to heat and agitate for another hour, the diphosphite Ni extraction coefficient was measured as 13.4 —a threefold increase.

Examples 12 and 13

These Examples demonstrate the effect of adding hexamethylene diamine (HMD) to the extraction zone.

Example 1 was repeated except that hexamethylene diamine was added to the product of a pentene-hydrocyanation reaction. To a 50 mL, jacketed, glass laboratory extractor, equipped with a magnetic stirbar, digital stir-plate, and maintained at 65° C., was charged 10 grams of the product of pentene-hydrocyanation reactor product, and 10 grams of the extract from the second stage of a mixer-settler cascade, operated in counter-current flow.

The reactor product was approximately:

85% by weight C₆ dinitriles

14% by weight C₅ mononitriles

1% by weight catalyst components

360 ppm by weight active nickel.

The laboratory reactor was then mixed at 1160 rotations-per-minute, for 20 minutes, and then allowed to settle for 15 minutes. A stable emulsion was present throughout the extract phase in the absence of the addition of HMD. After 15 minutes of settling, essentially no emulsion phase was present when HMD was added. Samples were obtained of the extract and raffinate phases of the extractor and analyzed to determine the extent of catalyst extraction.

TABLE 5 Effect of hexamethylene diamine on catalyst extraction Concentration of HMD added Catalyst Example (ppm) recovery (KLL) Stable emulsion 1 0 14 Yes 11 250 43 No 12 500 80 No

Example 14

A three stage counter-current liquid-liquid extractor, in continuous operation, utilizing the same two feed streams described in Example 1 was operated for a duration of 20 days. Samples were obtained of the extract and raffinate phases of the settling section of the extractor and analyzed to determine the extent of catalyst extraction. The ratio of active nickel present in the extract phase vs. the raffinate phase was found to be 5.6±2. A stable emulsion and rag was present throughout the extract portion of the settling section of the first stage of the extractor. The emulsion and rag was also present to a lesser extent in the settling sections of the second and third stages of the extractor.

Example 15

Example 14 was replicated except that a light-phase was recycled from the settling section back to the mixing section of the first stage of the countercurrent liquid-liquid extractor for a duration of 14 days.

The ratio of active nickel present in the extract phase vs. the raffinate phase was found to be 8.6±2. Less stable emulsion and rag was present throughout the extract portion of the settling section of the first stage of the extractor than in Example 14.

Example 16

Example 14 was replicated except that both light-phase recycle and heavy-phase were recycled in the first stage of the countercurrent liquid-liquid extractor for a duration of 60 days. Recycle of the light phase took place from the settler to the mixer in the manner described in Example 4. Recycle of the heavy phase took place from the settler and back to the settler in a manner which provided mild agitation to the mixed phase in the settler. The benefits of this type of recycle of a heavy phase are described in a copending application identified as (Attorney Docket No. PI2845).

The ratio of active nickel present in the extract phase vs. the raffinate phase was found to be 10.8±2. Less stable emulsion and rag was present throughout the extract portion of the settling section of the first stage of the extractor than in Example 15.

Results of Examples 14-16 are summarized in Table 6.

TABLE 6 Catalyst extraction coefficients for continuous operation using phase recycles. Stable Example Duration (days) Phase recycle KLL emulsion 14 20 None 5.6 ± 2 Yes 15 14 Light 8.6 ± 2 No 16 60 Light and Heavy 10.8 ± 2  No

Examples 14-16 illustrate the beneficial effect of recycling the light phase from the settler to the mixer, and the heavy phase from the settler back to the settler, of the settling section of the first stage of a multistage countercurrent liquid-liquid extractor while in continuous operation.

Examples 17, 18 and 19

These Examples demonstrate the effect of feeding pentenenitriles to the extraction zone.

To a 10 mL, glass laboratory extractor, equipped with a magnetic stirbar, digital stir-plate, and maintained at 65° C., was charged 2.5 grams of the product of pentene-hydrocyanation reactor product, 2.5 grams of the extract from the second stage of a mixer-settler cascade, operated in counter-current flow, and an additional 2.5 grams of stable-emulsion/rag removed from the first settling stage of the same mixer-settler cascade. The composition of the reactor product was the same as that given in Example 1.

Results of Examples 17-19 are summarized in Table 7.

TABLE 7 Effect of increasing pentenenitriles in the feed to catalyst extraction on stability of emulsion and rag. Example % PN in DN feed Stable emulsion 17 14 Yes 18 25 No 19 40 No

Examples 17-19 illustrate the beneficial effect of feeding pentenenitriles in the pentenenitrile-hydrocyanation reactor product on decreasing the stability of emulsions and rags during catalyst extraction. 

1. A process for recovering diphosphite-containing compounds from a feed mixture comprising diphosphite-containing compounds, organic mononitriles and organic dinitriles in a multistage countercurrent liquid-liquid extractor with extraction solvent comprising aliphatic hydrocarbon, cycloaliphatic hydrocarbon or a mixture of aliphatic and cycloaliphatic hydrocarbon, said process comprising: a) flowing the feed mixture to the first stage of the multistage countercurrent liquid-liquid extractor; and b) contacting the feed mixture with extraction solvent in the multistage countercurrent liquid-liquid extractor, wherein the first stage of the multistage countercurrent liquid-liquid extractor comprises a mixing section and a settling section, wherein a light phase separates from a heavy phase in the settling section, wherein the light phase comprises extraction solvent and extracted diphosphite-containing compounds, wherein the heavy phase comprises organic mononitriles and organic dinitriles, wherein a first portion of the light phase is withdrawn from the settling section and treated to recover diphosphite-containing compounds extracted into the light phase, and wherein a second portion of the light phase is withdrawn from the settling section and recycled to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor.
 2. The process of claim 1, wherein the recycle of the light phase to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor is sufficient to result in enhanced settling of the light phase and heavy phase in the settling section of the first stage.
 3. The process of claim 1, wherein the recycle of the light phase in the settling section of the first stage of the multistage countercurrent liquid-liquid extractor is sufficient to achieve at least one of the following results: (a) a reduction in the size of an emulsion phase in the settling section, based upon the size of the emulsion phase in the absence of recycle of the heavy phase; (b) an increase in the rate of settling in the settling section, based upon the rate of settling in the absence of recycle of the heavy phase; (c) an increase in the amount of diphosphite-containing compounds in the light phase, based upon the upon the amount of diphosphite-containing compounds in the light phase in the absence of recycle of the heavy phase; (d) a reduction in the size of a rag layer in the settling section, based upon the size of a rag layer in the settling section in the absence of recycle of the heavy phase; and (e) reduction in the rate of formation of a rag layer in the settling section, based upon the rate of formation of a rag layer in the settling section in the absence of recycle of the light phase.
 4. The process of claim 1, wherein the recycle of the light phase in the settling section of the first stage is sufficient to result in improved extraction of diphosphite-containing compounds based upon the extraction of diphosphite compounds in the absence of recycle of the light phase.
 5. The process of claim 1, wherein the extraction solvent recycle ratio (ESRR) is between 0.1 and 0.9, wherein ESRR is defined by the ratio of X to Y, wherein X is the mass per unit time of the second portion of the light phase recycled to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor, and wherein Y is the mass per unit time of all extraction solvent charged to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor.
 6. The process of claim 1, wherein the ESRR is between 0.2 and 0.8.
 7. A process according to claim 1 wherein the diphosphite-containing compound is a Ni complex with a diphosphite ligand selected from the group consisting of:

wherein in I, II and III, R¹ is phenyl, unsubstituted or substituted with one or more C₁ to C₁₂ alkyl or C₁ to C₁₂ alkoxy groups; or naphthyl, unsubstituted or substituted with one or more C₁ to C₁₂ alkyl or C₁ to C₁₂ alkoxy groups; and wherein Z and Z¹ are independently selected from the group consisting of structural formulae IV, V, VI, VII, and VIII:

and wherein R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, and R⁹ are independently selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy; X is O, S, or CH(R¹⁰); R¹⁰ is H or C₁ to C₁₂ alkyl;

and wherein R¹¹ and R¹² are independently selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy and CO₂R¹³, R¹³ is C₁ to C₁₂ alkyl, or C₆ to C₁₀ aryl unsubstituted or substituted with C₁ to C₄ alkyl; Y is O, S, or CH(R¹⁴); R¹⁴ is H or C₁ to C₁₂ alkyl;

wherein R¹⁵ is selected from the group consisting of H, C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy and CO₂R¹⁶, R¹⁶ is C₁ to C₁₂ alkyl, or C₆ to C₁₀ aryl, unsubstituted or substituted with C₁ to C₄ alkyl, and wherein for structural formulae I through VIII, the C₁ to C₁₂ alkyl, and C₁ to C₁₂ alkoxy groups may be straight chain or branched.
 8. The process of claim 1 wherein at least one stage of the extraction is carried out above 40° C.
 9. The process of claim 1, wherein at least one stage contains a Lewis base.
 10. The process of claim 9 wherein the Lewis base is a monodentate triarylphosphite wherein the aryl groups are unsubstituted or substituted with alkyl groups having 1 to 12 carbon atoms, and wherein the aryl groups may be interconnected.
 11. The process of claim 9 wherein the Lewis base is selected from the group consisting of: a) anhydrous ammonia, pyridine, alkylamine, dialkylamine, trialkylamine wherein the alkyl groups have 1 to 12 carbon atoms; and b) polyamine.
 12. The process of claim 11 wherein the polyamine comprises at least one selected from hexamethylene diamine and dimers and trimers of hexamethylene diamine.
 13. The process of claim 11 wherein the polyamine comprises dimers of hexamethylene diamine.
 14. The process of claim 9 wherein the Lewis base compound is Amberlyst 21® resin.
 15. The process of claim 1 wherein the extraction solvent is cyclohexane.
 16. The process of claim 1 wherein at least a portion of the process is carried out in an extraction column or a mixer-settler.
 17. The process of claim 1 wherein the feed mixture is an effluent stream from a hydrocyanation process.
 18. The process of claim 14 wherein the hydrocyanation process includes a 3-pentenenitrile hydrocyanation process.
 19. The process of claim 15 wherein the hydrocyanation process includes a 1,3-butadiene hydrocyanation process.
 20. The process of claim 1 wherein the feed mixture is an effluent stream from a hydrocyanation process and the concentration of pentenenitriles in the feed to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor, is sufficient to result in enhanced settling of the light phase and heavy phase in the settling section of the first stage, and a reduction in stable emulsion and rag.
 21. The process of claim 20 wherein the concentration of pentenenitriles in the feed to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor is greater than 12 weight %.
 22. The process of claim 20 wherein the concentration of pentenenitriles in the feed to the mixing section of the first stage of the multistage countercurrent liquid-liquid extractor is between 15 and 30 weight %. 